Free casting method, free casting apparatus, and casting

Patent metadata

Field	Value
Publication number	US-9120146-B2
Application number	US-201113821727-A
Country	US
Kind code	B2
Filing date	Sep 12, 2011
Priority date	Sep 17, 2010
Publication date	Sep 1, 2015
Grant date	Sep 1, 2015

Abstract

A free casting method according to the present invention includes, a lead-out step for leading out molten metal from a lead-out area provided in a source of supply, e.g. a surface level of the molten metal, to retain the molten metal temporarily by surface films generated on an outer surface, and a forming step for obtaining a formed body by solidifying retained molten metal led out along a set passage depending on a desired casting shape, wherein the retained molten metal is solidified after being formed into the desired casting shape by applying an external force thereto at positions between an unrestrained root portion of the retained molten metal in vicinity of the surface level of the molten metal and a solidification interface defined as a boundary between the retained molten metal and the formed body in the forming step.

First claim

The invention claimed is:

1. A free casting method for making a casting free of a casting mold, the method including:
drawing molten metal up from a surface level of a molten metal in a crucible along a set passage;
forming a surface film generated by a surface tension on an outer surface of the molten metal along the set passage;
retaining the molten metal drawn up from the surface level of the molten metal in the crucible within the surface film to form an unrestrained root portion of the retained molten metal at an interface between the surface level of the molten metal in the crucible and the retained molten metal in the set passage; and
forming a solidified formed body at a solidification interface between the unrestrained root portion of the retained molten metal in the set passage and the formed body by solidifying the retained molten metal in the set passage depending on a desired casting shape of the formed body and moving the unrestrained root portion of the unsolidified retained molten metal with respect to the solidified formed body along the surface level.

2. The free casting method as claimed in claim 1 , wherein the drawing up step includes bringing an inducing body for inducing a basic shape of the casting into contact with the molten metal as the molten metal is being drawn up from the crucible.

3. The free casting method as claimed in claim 1 , wherein the forming step includes lifting the retained molten metal upward along the set passage.

Assignees

• Yaokawa Jun
• Iwata Yasushi
• Sugiyama Yoshio
• Iwahori Hiroaki
• Amano Norihiro
• Ueno Noriyuki
• Kobayashi Takehito
• Toyota Chuo Kenkyusho Kk
• Toyota Motor Co Ltd

Inventors

• Yaokawa Jun
• Iwata Yasushi
• Sugiyama Yoshio
• Iwahori Hiroaki
• Amano Norihiro
• Ueno Noriyuki
• Kobayashi Takehito

Classifications

• B22D11/145 Primary

  for upward casting · CPC title

• B22D11/01 Primary

  without moulds, e.g. on molten surfaces · CPC title

• B22D11/05

  into moulds having adjustable walls · CPC title

• B22D27/045

  Directionally solidified castings · CPC title

• B22D11/041

  for vertical casting (B22D11/043, B22D11/049 - B22D11/059 take precedence) · CPC title